Removing and installing fuel delivery unit, four wheel drive — VW

AEY AFN 1Y 1Z AHU ALE AVG
Notes:

Always renew self-locking nuts.
Always renew corroded bolts/nuts.
Rear axle tightening torque:

=> Running gear; Repair group 42; Assembly overview rear axle, vehicles with four wheel drive
Running gear
Assembly overview rear axle, vehicles with four wheel drive

Observe safety precautions => Page
20-10
.
Observe safety precautions => Page
20-11
.

Note:

Check whether a coded radio is installed as during the forthcoming work sequences the battery earth strap must be disconnected. Obtain radio code first if necessary.

Special tools, workshop equipment, testers, measuring instruments and auxiliary items required

Gearbox jack V.A.G 1383 A

Removing

With ignition switched off disconnect battery earth strap.
Drain fuel tank.
Loosen both rear wheel securing bolts.
Remove cap, retaining ring and rubber cup from fuel filler neck.

Remove cover in luggage boot floor.
Pull connector and supply and return pipes off flange.

Unclip ABS sensor wire connectors (if fitted) from retainers under rear seat -arrows- and guide the rubber grommets through the floor plate.

Note:

Makes it possible to lower the rear axle.

Unhook handbrake cable -arrows A- from retainers.
Unhook exhaust system -arrows B- from axle beam.
Unclip brake pipes -arrow C- from the retainer.
Disconnect propshaft -1- from the viscous coupling -2- flexible joint (first mark fitting position).

Pull vent pipe -1- out of wiring loom insulation tubing.
Pull connector off the positioning element.

Place engine and gearbox jack V.A.G 1383A under final drive.
Remove securing bolts -arrows- from final drive mounting bracket on cross member -1-.

Disconnect wishbone from shock absorber -arrow-.

Remove bolts -A- and -B-.

Lower rear axle with engine and gearbox jack V.A.G 1383A
and separate propshaft from the viscous coupling with a lever.

Note:

When lowering ensure that the viscous coupling centralizing nut -arrow- in the propshaft is not canted and that the oil seal in the propshaft is not damaged.

When lowering set the angle of the engine and gearbox jack plate -2- so that the rear of the final drive lowers first.

Remove filler neck securing bolts -1- .
Pull hoses off from return pipe -2- from gravity valve and vent pipe -3- to vent valve of filler neck.

Golf Estate:

Wiring connections => Page
20-10
, Fig.
3

Remove fuel tank securing straps.
Remove fuel tank heat shield, first remove rear silencer mounting.
Remove cross-brace under fuel tank.

Note:

When removing the cross-brace the fuel tank must be supported.

Take out fuel tank downwards.

Installing

Installation is done in the reverse sequence.